Apparatus and method for cleaning poultry

ABSTRACT

An apparatus ( 10 ) for washing eviscerated poultry carcasses ( 12 ) has a housing ( 11 ), a conveyor ( 15   a ) for moving the shackled poultry carcasses through the housing. A guide bar ( 24 ) tilts the poultry carcasses ( 12 ) from a vertical position for spraying by a first set of nozzles ( 23 ). The first set of nozzles ( 23 ) delivers a cleaning solution ( 100 ) at a sufficient flow rate and line pressure, whereby a portion of the cleaning solution ( 100 ) is deflected back out the rear opening ( 12   d ) of the poultry carcass ( 12 ).

CROSS-REFERENCE TO RELATED APPLICATION(S)

This application is a continuation of U.S. application Ser. No.11/903,889, filed Sep. 25, 2007, published as US2008-0020694, nowallowed, which is a division of U.S. application Ser. No. 10/755,089,filed on Jan. 8, 2004, now issued as U.S. Pat. No. 7,288,274. The entiredisclosures of which are hereby expressly incorporated herein byreference including, without limitation, the specification, claims, andabstracts, as well as any figures, tables, or drawings thereof.

BACKGROUND

This invention relates to an apparatus and method for cleaning poultryand more particularly to an apparatus and method wherein a diffusedstream of cleaning fluid enters the rear end opening of an evisceratedpoultry carcass from a direction, and at a sufficient volume over time,so that the cleaning fluid is deflected out the rear end opening andbeneath loose-hanging tissue hereafter referred to as “abdominal fatflaps”.

All poultry carcasses entering the processing environment arecontaminated with bacteria, some with pathogenetic bacteria such asSalmonella. Fecal matter, poultry litter and dirt are the main sourcesof this contamination. As a result of such contamination, poultry istypically washed at any of several steps during the process ofconverting a live bird to an edible food product. Such washing aims toremove dirt, offal, blood, viscera, other debris and microbes from thepoultry. Removing or reducing microbes aids the safe storage andconsumption of poultry, yet many existing washing procedures fail tosignificantly reduce the microbe burden on poultry. The potential forpoultry skin to become cross-contaminated is worsened by the ability ofall types of bacteria to adhere within only 15 seconds of contact. Oncein the processing environment, a significant number of carcasses canbecome cross-contaminated with pathogens during handling, scalding,mechanical processing and chilling. Current methods for many of thoseprocedures also fail to significantly reduce the microbe burden onpoultry.

One method of cleaning the poultry is the use of inside-outside birdwashers. Such inside-outside bird washers wash the inside cavity byspraying a cleaning fluid through a probe inserted into the cavity whilethe carcass travels along a conveyor. While such washers are useful,there is always the possibility of cross contamination because of theprobe being inserted into the cavity of one bird and then into a cavityof another bird. Another method of cleaning poultry is the use of floodwashers. Flood washers wash the cavity by filling the cavity with anon-defused stream of cleaning fluid via flood nozzles while the carcasstravels along a conveyor. Other types of washers spray the poultry onthe outside and inside of the cavity, with the cleaning solution sprayedinside of the cavity draining out the neck opening, as the poultry ishung upside down by its legs. The use of a peroxyacetic acid andperoxyoctanoic acid, as described in U.S. Pat. No. 6,514,556, has beeneffective in reducing microbial contamination in poultry.

In cleaning the poultry carcass, an additional problem is the abdominalfat flaps. These flaps are the result of a midline cut of the abdominalskin between the breast bone and the cloaca (anus) that allows viscerato be removed. These two flaps are adjacent to the rear opening and aredifficult to clean. Further, they tend to trap the bacteria or othercontaminants that are attempting to be cleaned. The flaps are connectedto the side of the rear opening and flop over the opening. The prior artflood methods do not have a good mechanism for cleaning underneath theflaps because they apply the cleaning solution on top of the flaps whilethe carcass is hanging by the legs in a vertical position. When thecarcass is hanging vertical, the natural condition of the flaps is tofall inside the cavity creating a pocket that is shielded from cleaning.Applying the cleaning solution on top of the flaps reduces their abilityto be lifted up so the pocket area can be cleaned. It has often beenfound that when there are problems with cleaning efficacy, it was due toinsufficient cleaning/sanitizing of the inside cavity.

While the foregoing have proved useful and effective in reducingmicrobial contamination in poultry, it is always advantageous to provideadvancements in the development of the reducing of the microbialcontamination.

SUMMARY

In one embodiment, the invention is a method of washing evisceratedpoultry carcasses. The poultry carcasses have legs, an exterior surface,a cavity having a rear end opening and a neck end. The method includesconveying the carcasses, hung by the legs, through a housing. The cavityis sprayed with a cleaning fluid that enters the rear end opening from adirection and at a sufficient volume over time whereby a portion of thecleaning solution is deflected out of the rear end opening. The exteriorsurface is sprayed with a cleaning solution.

In another embodiment, the invention is an apparatus for washingeviscerated poultry carcasses having legs, an exterior surface, a cavityhaving a rear end opening and a neck end. The apparatus includes aconveyor for conveying the poultry carcasses. A housing has an inlet andan outlet through which the poultry carcasses pass. A guide bar ispositioned in the housing and positioned to contact the poultrycarcasses and raise the neck ends to tilt the poultry carcasses fromvertical. A first set of multiple spray nozzles provide for a diffusedstream of cleaning fluid into the cavity from a direction and at asufficient volume over time, whereby a portion of the cleaning fluid isdeflected out the rear opening and beneath the flaps and a second set ofmultiple spray nozzles are provided for spraying the exterior surfacewith a cleaning solution.

In another embodiment, the invention is a method of washing evisceratedpoultry carcasses, the poultry carcasses having legs, an exteriorsurface, a cavity having a rear-end opening, and a neck end. The methodincludes conveying the carcasses, hung by the legs, through a housing.The cavity is sprayed with a cleaning fluid that enters the rear endopening, the cavity having a volume and a volume of the cleaningsolution being at least one-fourth of the volume of the cavity. In apreferred embodiment, the cleaning fluid enters in less than 0.4seconds.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a perspective view of the apparatus for cleaning poultryaccording to the present invention;

FIG. 2 is a sectional view of the apparatus shown in FIG. 1, takengenerally along the lines 2-2;

FIG. 3 is a sectional view of the apparatus shown in FIG. 1, takengenerally along the lines 3-3;

FIG. 4 is a top plan view of the apparatus shown in FIG. 1;

FIG. 5 a is a view of the inferior and anterior (partial) surfaces of achicken with the abdominal fat in a closed (inward) position;

FIG. 5 b is a view of the inferior and anterior (partial) surfaces of achicken with the abdominal fat in an open (outward) position;

FIG. 6 a is a midsagittal view of a chicken showing the closed positionof the abdominal fat prior to spraying;

FIG. 6 b is a midsagittal view of a chicken showing the open position ofthe abdominal fat during spraying and the abdominal fat flaps beingmoved away from the rear end opening; and

FIG. 7 is an enlarged portion of FIG. 4, showing an oscillating conduit.

DETAILED DESCRIPTION

Referring to the drawings, wherein like numerals represent like partsthroughout the several views, there is generally disclosed at 10 anapparatus for washing eviscerated poultry carcasses. The apparatus 10uses a cleaning fluid or solution to clean poultry carcasses, thecleaning solution may be any suitable solution and may include water, orwater with chemicals added. In addition, the cleaning solution mayinclude peroxyacetic acid and peroxyoctanoic acid as described in U.S.Pat. No. 6,514,556 entitled “Method and Composition for Washing PoultryDuring Processing”, which is hereby incorporated by reference. It isunderstood that any suitable cleaning agent, antimicrobial agent,detergent, surfactant, chelating agent, defoaming agent, polyphosphate,acidulant, alkali or water softening/conditioning agent may be utilizedwith the present invention. Examples of these agents are peroxygens,chlorinated compounds, organic acids, chlorine dioxide, acidified sodiumchlorite, and trialkali metal orthophosphates.

The apparatus 10 includes a housing 11 that defines a housing interior11 a through which the eviscerated chickens 12 are conveyed. Thefollowing description is directed to a chicken, but it is understoodother poultry may be washed and the chicken is shown to specificallyshow just one type of poultry. The chickens 12 have an exterior surface12 a, a cavity 12 b having a rear end opening 12 c and a neck end 12 dhaving a neck opening 12 e. The neck end 12 d may have an opening 12 eif the carcass has gone through the neck puller operation. This can bedone either before or after the washing. The chickens 12 have a firstabdominal fat flap 13 and a second abdominal fat flap 14. Both abdominalfat flaps 13, 14 have a free end 13 a and 14 a and a connected end 13 b,14 b. The connected ends are connected to the chicken proximate the rearend opening 12 c. As will be discussed more fully hereafter, FIGS. 5 aand 6 a show the abdominal fat flaps 13, 14 in a generally closedposition and FIGS. 5 b and 6 b show the abdominal fat flaps 13, 14 in agenerally open position. The abdominal fat flaps have an interiorsurface 13 c, 14 c and an exterior surface 13 d, 14 d.

The housing 11 also has a rectangular slot or opening 11 b. The opening11 b is positioned to allow shackles 15 to be moved, by an overheadconveyor 15 a, through the apparatus 10. The chickens 12 are held in theshackles 15 by their legs 12 f. The overhead conveyor 15 a and shackles15 are typically permanently positioned in a processing facility. Theapparatus 10 has a first section, generally designated at 16 and asecond section, generally designated at 17. The first section 16 isutilized to clean the cavity 12 b and the exterior surface 12 a, whilethe second section 17 is utilized to clean the exterior surface 12 aafter the bacteria or other contaminants have been cleaned out of thecavity 12 b. This arrangement is preferable, although it is understoodthat the functions of the two sections 16, 17 could be combined into onesection.

Referring to FIGS. 2 and 4, the housing 11 includes an inlet manifold 18that is in fluid communication and provides cleaning solution 100 tofive conduits 19-23. Conduits may be added or subtracted and thelocation of conduits within the housing 11 may change. Conduits may berotated to allow spray nozzle 19 a-23 a aim adjustment and may beconnected to a mechanism that moves the conduits in an oscillatingmotion. The conduits are supported in the housing interior 11 a by meanswell known in the art and are not shown. The conduits 19-23 run thelength of the first section 16. A plurality of spray nozzles 19 a-23 aare operatively connected to the conduits 19-23 by means well known inthe art. Typically, an elbow fitting connects the conduit to the spraynozzle, such construction being well known in the art. The nozzles 19a-23 a have discharge orifices that diffuse the stream of the cleaningsolution. A guide bar 24 is suitably supported in the housing interiorto contact the anterior or posterior side of the carcasses to tilt thecarcasses from vertical. As seen in FIG. 2, the guide bar 24 is suitablysupported in the housing interior 11 a. As seen in FIG. 2, the carcassguide bar 24 is connected by suitable means, such as welding, to thesupport tubes 27. The support tubes 27 are connected to pivotingsupports 26 by sliding the support tubes 27 over the pivoting supports26 and fastening by means well known in the art that allow adjustment,such as bolting or threaded screw. The pivoting supports 26 areconnected to mounting supports 25 by a pivot joint 26 a well known inthe art. Mounting supports 25 are connected to the housing 11 by meanswell known in the art such as welding.

Referring to FIGS. 3 and 4, the second section 17 has a second inletmanifold 28, which is similar to inlet manifold 18 and is connected to asource of cleaning solution 100. The inlet manifold 28 is operativelyconnected and in fluid communication to six conduits 29-34. Nozzles 29a-34 a are operatively connected to and in fluid communication with theconduits 29-34. The nozzles 29 a-34 a are similar to nozzles 19 a-22 a.The conduits 29-34 extend generally along the length of section 17. Theconduits 31-34 are oscillating conduits while conduits 29, 30 as well as19-23 are fixed. Oscillating conduits are well known in the art. FIG. 7shows a schematic representation of a typical oscillating conduit. Theoscillating mechanism includes a conduit 31 with a nozzle 31 a in fluidcommunication therewith. A flange 35 is operatively connected to theconduit 31. The flange 35 is connected by a length 36 to a motor 37. Themotor 37 causes the link 36 to move and down, thereby rotating theconduit 31. As previously mentioned, the second section 17 may beincorporated into the first section 16, if desired

As can be seen in FIG. 4, there is a plurality of exterior surface spraynozzles 19 a-22 a and 29 a-34 a aimed at the exterior surface 12 a and aplurality of cavity spray nozzles 23 a aimed at the rear end opening 12c and abdominal fat flaps 13, 14. The number of nozzles depends on thenumber and length of the conduits 19-23 and the desired cleaningoutcome. Preferably, there are at least three nozzles 23 a in linearsequence and preferably between 5 to 9 nozzles 23 a.

The following are values for the nozzles 19 a-23 a and 29 a-34 a. It isunderstood that the critical values are for the nozzle 23 a, as theother nozzles 19 a-22 a and 29 a-34 a are well known. The values are formoving the carcasses at a line speed of 14 inches per second.

TABLE 1 Preferred More Preferred Cavity Spray Nozzles 23a Flow rate 3 to15 gallons per 5 to 12 gallons per minute minute Line pressure 10 to 20psi 15 to 20 psi Nozzle spacing (in linear 1 to 6 inches 1 to 3 inchessequence on conduit) Spray distance (from spray 4 to 15 inches 6 to 10inches orifice to poultry) Diffused spray angle 10 to 40 degrees 15 to25 degrees Spray pattern Full cone or Flat Flat Exterior Surface SprayNozzles 19a-22a; 29a-34a Flow rate 0.2 to 2 gallons per 0.4 to 1 gallonper minute minute Line pressure 20 to 60 psi 30 to 50 psi Nozzle spacing4 to 18 inches 6 to 12 inches Spray distance 4 to 18 inches 6 to 12inches Diffused spray angle 10 to 75 degrees 25 to 60 degrees Spraypattern Full cone or Flat Flat

As can be seen, the line pressure for conduit 23 is different thanconduits 19-22. Since the conduits 19-23 are all being fed from the sameconduit 18, a flow restrictor (not shown) is positioned in the conduit23 to provide appropriate line pressure. It is, of course, understoodthat a separate conduit could be utilized to supply this different linepressure. Further, while all nozzles have been described and shown aslinear or substantially linear, it is understood that they may also benon-linear.

An effective method to wash the cavity of an eviscerated poultry carcasswith a diffused spray stream originating from outside the carcass is todeliver at least 1 volume of cleaning solution for every four poultrycavity volumes in less than 0.4 second and preferably less than 0.36seconds or less. That is, if the poultry cavity is 240 mL, at least 60mL of solution into the cavity.

The preferred method to wash the cavity of an eviscerated poultrycarcass with a diffused spray stream originating from outside thecarcass is to deliver at least 1 volume of cleaning solution for everythree poultry cavity volumes in less than 0.4 second and preferably lessthan 0.36 seconds or less. By supplying the cleaning solution in theratios and times previously described, the cleaning solution isdeflected back out the cavity for the cleaning to be described hereafterwith respect to FIG. 6 b.

For either method, it is preferred that the spray stream enters thecavity at an angle approximately perpendicular to the spinal column ofthe carcass. For either method, it is preferred that multiple spraystreams in linear sequence are used. Further, it is preferred that thespray streams be 6 inches or less apart. For either method, it ispreferred that the spray stream enters the cavity of a carcass that isin a non-vertical position. Further, if the carcass is hanging verticalby the legs from a shackle, it is preferred that the carcass be tiltedto a non-vertical position while the spray stream is applied.

In operation, the chicken carcasses 12 are hung by their legs 12 f suchthat the rear end opening 12 c is up and the neck end 12 d is down. Theshackles 15 are moved on the overhead conveyor 15 a such that thechicken carcasses 12 enter the housing interior 11 a. Shackle guides 38,well known in the art, are also provided to guide the shackles intoopening 11 b. The chicken carcasses 12 enter the housing generallyvertical. Then, as viewed in FIG. 2, the carcasses contact the guide bar24 to tilt the chicken carcasses 12 from the vertical. This makes iteasier for the abdominal flaps 13, 14 to deflect outward and allowsbetter cleaning beneath the flaps. While the guide bar 24 is notnecessary, it does assist in the better functioning of the apparatus 10.The bird tilt provided is shown at about 15 degrees from vertical and ispreferably from 10 degrees to 45 degrees. The cleaning solution 100,which is being supplied under the conditions noted previously, cleansthe exterior surface 12 a and also the cavity 12 b. However, the innercavity 12 b is cleaned in a manner different than that known in theprior art. The cleaning solution is applied as a diffused spray streamoriginating from outside the carcass and delivers at least 1 volume ofcleaning solution into the cavity 12 b for every four poultry cavityvolumes in less than 0.4 seconds. It is preferred that the spray streamenters the cavity at an angle approximately perpendicular to the spinalcolumn of the carcass. It is also preferred that multiple spray streamsin linear sequence are used, those streams being 6 inches or less apart.The stream does not fill the cavity, but instead a portion of thecleaning fluid is deflected out the rear end opening 12 c and beneaththe flaps 13, 14. This allows for better cleaning beneath the abdominalfat flaps 13, 14. This action is schematically shown in FIGS. 6 a, 6 b.

FIG. 6 a shows the chicken carcass 12 after it has been moved fromvertical by the guide bar. This presents the rear end opening 12 cbetter to the nozzle 23 a. In this closed position, the abdominal flaps13, 14 tend to overlie each other and close off the cavity 12 b. Thecleaning fluid is preferably supplied from the ventral side (as seen inFIG. 1) to the rear end opening 12 c, although from other sides willalso be acceptable.

Then, in FIG. 6 b, the effect of the cleaning solution 100 being sprayedfrom the nozzle 23 a is shown. It is understood from previousdiscussions that the nozzle 23 a is preferably six to ten inches awayfrom the opening 12 c. The cleaning solution 100 is supplied underconditions which cause the cleaning solution 100 to deflect back out ofthe rear end opening 12 c after the cleaning solution has hit otherportions of the side walls of the cavity 12 b. The stream of cleaningsolution is going in a stream inside the cavity and the stream isdeflected from the inward movement, the usual direction, to be moving inanother direction that is back outside of the cavity. There is someaccumulation 100 a of the cleaning solution 100 at the bottom of thecavity 12 b. This accumulation 100 a will tend to exit out of the neckopening 12 e or later be discharged when the carcass is removed from theshackles. The remaining cleaning solution 100 is deflected out undersuch conditions as to cause the abdominal flaps 13, 14 to go into theopen position (FIG. 5 b). The solution is deflected back out andcontacts the interior surface of the abdominal fat and raises theabdominal fat to effectively remove any pockets that may form to trapcontaminants. This provides for effective cleaning of the bacteria orother contaminants which may exist under the abdominal flaps 13, 14. Theconditions under which the cleaning solution 100 is supplied have beenpreviously discussed with respect to time and volume. It is understoodthat these or other suitable combinations, based on the particularconfigurations of the assembly line and the chicken carcasses 12 mayvary the conditions. However, the cleaning solution is supplied undersuch conditions as to not just float the abdominal flaps slightly up asthe cavity 12 b is flooded, as in the prior art, but instead theabdominal flaps are deflected up such that their free ends 13 a, 14 amove from a closed position (FIG. 5 a) to a position where the free ends13 a, 14 a are in an open position (FIG. 5 b).

EXAMPLES

In all examples, spray nozzles 23 a (Spraying Systems Co. VeeJet® spraynozzles) in linear sequence were used to spray diffused water streamsinto the cavity of an eviscerated chicken carcass moving past thenozzles. The spray stream entered the cavity at an angle approximatelyperpendicular to the spinal column of the carcass. The carcass had a 240mL cavity volume. Spray nozzles were spaced on either 3- or 6-inchcenters.

Results were recorded as follows:

0=Not effective (spray deflected in the cavity, sometimes out the rearend opening, the abdominal fat flaps in a closed position)+=Effective cavity washing (spray deflected in the cavity, out the rearend opening, the abdominal fat flaps sometimes in an open position)++=More effective cavity washing (spray deflected out of the cavity, outthe rear end opening, the abdominal fat flaps in an open position)

Example 1 0.18 Second Exposure Time to Each Spray Stream (6 Inches onCenter)

Volume of Water (to Nearest 10 mL) Delivered Into the Cavity per SprayStream Line Pressure 30 mL 40 mL 60 mL 80 Ml 10 psig 0 0 + ++ 20 psig 00 + ++

Example 2 0.18 Second Exposure Time to Each Spray Stream (3 Inches onCenter)

Volume of Water (to Nearest 10 mL) Delivered Into the Cavity per SprayStream Line Pressure 30 mL 40 mL 60 mL 80 mL 10 psig 0 + + ++ 20 psig0 + ++ ++

Example 3 0.36 Second Exposure Time to Each Spray Stream (6 Inches onCenter)

Volume of Water (to Nearest 10 mL) Delivered Into the Cavity per SprayStream Line Pressure 40 mL 60 mL 80 mL 110 mL 10 psig 0 + ++ ++ 20psig + + ++ ++

Example 4 0.36 Second Exposure Time to Each Spray Stream (3 Inches onCenter)

Volume of Water (to Nearest 10 mL) Delivered Into the Cavity per SprayStream Line Pressure 40 mL 60 mL 80 mL 110 mL 10 psig 0 + ++ ++ 20 psig0 + ++ ++

The above specification, examples and data provide a completedescription of the manufacture and use of the composition of theinvention. Since many embodiments of the invention can be made withoutdeparting from the spirit and scope of the invention, the inventionresides in the claims hereinafter appended.

1. An apparatus for washing eviscerated poultry carcasses having legs,an exterior surface, abdominal fat flaps a cavity having a rear endopening and a neck end, comprising: a) a conveyor for conveying thecarcasses; b) a housing having an inlet and an outlet through which thecarcasses pass; c) a guide bar positioned in the housing and positionedto contact the carcasses and raise their neck ends to tilt the poultrycarcasses from vertical; d) a first set of multiple spray nozzles forproviding a diffused stream of cleaning fluid into the cavity from adirection and at a sufficient flow rate, whereby a portion of thecleaning fluid is deflected out the rear end opening and beneath theabdominal fat flaps; and e) a second set of multiple spray nozzles forspraying the exterior surface with a cleaning solution.
 2. The apparatusof claim 1, the carcasses having abdominal fat flaps proximate the rearend opening, the deflected cleaning solution resulting in movement of anunattached end of the abdominal fat flaps outward and away from the rearend opening by the deflected cleaning fluid.
 3. The apparatus of claim2, the second set of nozzles are oscillating.
 4. The apparatus of claim2, wherein the cleaning fluid flows at a rate of at least three gallonsper minute from each nozzle of the first set of multiple spray nozzlesand at a line pressure of at least 10 psi.
 5. The apparatus of claim 4,the first set of multiple spray nozzles having a 10 degree or greaterspray angle and spaced from a distance of from 6 to 10 inches from therear end opening.
 6. The apparatus of claim 5, the first set of nozzlescomprising at least three spray nozzles.
 7. The apparatus of claim 6,the second set of nozzles having a flow rate from each nozzle of atleast 0.2 gallons per minute and a line pressure of 20 psi or greater.